Systems and methods for assembling elongate composite structures

ABSTRACT

Systems and methods for assembling elongate composite structures are disclosed. The systems include a first rigid elongate cure tool defining a first elongate support surface for supporting a first elongate charge of composite material (FEC), a second rigid elongate cure tool defining a second elongate support surface for supporting a second elongate charge of composite material (SEC), and a flexible elongate caul plate. The systems further include a vacuum compaction film, a translation structure, and a vacuum source. Methods according to the present disclosure include positioning a vacuum compaction film, positioning a flexible elongate caul plate, and positioning an FEC. The methods further include positioning an SEC, contacting a region of the FEC with a region of the SEC, sealing the vacuum compaction film, evacuating the enclosed volume to generate an elongate composite assembly, and heating the elongate composite assembly to define the elongate composite structure.

FIELD

The present disclosure is directed generally to systems and methods forassembling elongate composite structures and more particularly tosystems and methods that utilize a vacuum compaction device and anelongate caul plate to compact charges of composite material.

BACKGROUND

Assembly of a composite structure may involve joining two elongatecharges of composite material to one another, such as under heat and/orpressure. For example, the assembling may involve locating the twoelongate charges of composite material on respective elongate cure toolsand urging the elongate cure tools toward one another to compact andbind the charges of composite material to one another.

While such a process may be effective in some circumstances, it may beineffective in others. As an example, the elongate cure tools may berelatively rigid. As such, the elongate cure tools may not effectivelycompact the two elongate charges of composite material to one another inregions where a thickness of the two elongate charges of compositematerial varies. Stated another way, the elongate cure tools may beineffective at uniformly compacting the two elongate charges ofcomposite material together, especially in regions where a thickness of,or number of plies contained within, a portion of the two elongatecharges of composite material that extends between the elongate curetools varies.

As a size and/or length of the two elongate charges of compositematerial and/or of the elongate cure tools increases, the compactionuniformity may decrease. Thus, there exists a need for improved systemsand methods for assembling elongate composite structures.

SUMMARY

Systems and methods for assembling elongate composite structures aredisclosed. Systems according to the present disclosure include a firstrigid elongate cure tool defining a first elongate support surfaceconfigured to support a first elongate charge of composite material(FEC) and a second rigid elongate cure tool defining a second elongatesupport surface configured to support a second elongate charge ofcomposite material (SEC). At least a region of the second elongatesupport surface faces toward a corresponding region of the firstelongate support surface. The systems further include a flexibleelongate caul plate extending along the first elongate support surfaceand configured to extend between, and spatially separate, the firstelongate support surface and the FEC, as well as a vacuum compactionfilm at least partially defining an enclosed volume that includes theFEC, the SEC, and the flexible elongate caul plate. A region of thevacuum compaction film extends between, and spatially separates, theflexible elongate caul plate and the first elongate support surface. Thesystems additionally include a translation structure configured topermit relative translation between the first rigid elongate cure tooland the second rigid elongate cure tool between a first relativeorientation, in which the FEC is spaced-apart from the SEC, and a secondrelative orientation, in which the FEC contacts the SEC. The systemsalso include a vacuum source configured to apply a vacuum to theenclosed volume.

Methods according to the present disclosure include positioning a vacuumcompaction film on a first elongate support surface of a first rigidelongate cure tool, positioning a flexible elongate caul plate on thefirst elongate support surface such that the vacuum compaction filmextends between, and spatially separates, the flexible elongate caulplate and the first elongate support surface, and positioning a firstelongate charge of composite material (FEC) on the first elongatesupport surface such that the vacuum compaction film and the flexibleelongate caul plate extend between, and spatially separate, the FEC andthe first elongate support surface. The methods further includepositioning a second elongate charge of composite material (SEC) on asecond elongate support surface of a second rigid elongate cure tool,contacting a region of the FEC with a region of the SEC to define aninterface region between the FEC and the SEC, and sealing the vacuumcompaction film against at least one of the first elongate supportsurface and the second elongate support surface to at least partiallydefine an enclosed volume that includes the FEC, the SEC, and theflexible elongate caul plate. The methods additionally includeevacuating the enclosed volume to compact the FEC and the SEC, to pressthe FEC and the SEC against one another, and to generate an elongatecomposite assembly that includes the FEC, the SEC, the vacuum compactionfilm, the first elongate cure tool, and the second elongate cure tool.The methods further include heating the elongate composite assembly tocure the FEC and the SEC, to join the FEC to the SEC within theinterface region, and to define the elongate composite structure fromthe FEC and the SEC.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an example aircraft that includes acomposite structure that may be formed by the systems and methods of thepresent disclosure.

FIG. 2 is a perspective cutaway view of an example wing of the aircraftof FIG. 1.

FIG. 3 is a schematic elevation view representing systems for assemblingelongate composite structures.

FIG. 4 is a schematic cutaway plan view representing a portion ofsystems for assembling elongate composite structures.

FIG. 5 is a schematic elevation view representing a portion of a systemfor assembling elongate composite structures.

FIG. 6 is a schematic elevation view representing a portion of a systemfor assembling elongate composite structures.

FIG. 7 is a flowchart schematically representing methods of assemblingelongate composite structures.

FIG. 8 is a schematic elevation view representing a portion of a systemfor assembling elongate composite structures during assembly of anelongate composite structure.

FIG. 9 is a schematic elevation view representing a portion of thesystem of FIG. 8 during assembly of the elongate composite structure.

FIG. 10 is a schematic elevation view representing a portion of thesystem of FIG. 8 during assembly of the elongate composite structure.

FIG. 11 is a schematic elevation view representing a portion of thesystem of FIG. 8 during assembly of the elongate composite structure.

FIG. 12 is a schematic elevation view representing a portion of thesystem of FIG. 8 during assembly of the elongate composite structure.

FIG. 13 is a schematic elevation view representing a portion of thesystem of FIG. 8 during assembly of the elongate composite structure.

FIG. 14 is a schematic elevation view representing a portion of a systemfor assembling elongate composite structures during assembly of aelongate composite structure.

FIG. 15 is a schematic elevation view representing a portion of thesystem of FIG. 14 during assembly of the elongate composite structure.

FIG. 16 is a schematic elevation view representing a portion of thesystem of FIG. 14 during assembly of the elongate composite structure.

FIG. 17 is a schematic elevation view representing a portion of thesystem of FIG. 14 during assembly of the elongate composite structure.

FIG. 18 is a schematic elevation view representing a portion of thesystem of FIG. 14 during assembly of the elongate composite structure.

FIG. 19 is a schematic elevation view representing a portion of thesystem of FIG. 14 during assembly of the elongate composite structure.

FIG. 20 is a flowchart schematically representing aircraft productionand service methodology.

FIG. 21 is a block diagram schematically representing an aircraft.

DESCRIPTION

FIGS. 1-21 provide illustrative, non-exclusive examples of systems 20and/or methods 200 for assembling an elongate composite structure 800,according to the present disclosure, and/or of aircraft 700 includingthe elongate composite structure. Elements that serve a similar, or atleast substantially similar, purpose are labeled with like numbers ineach of FIGS. 1-21, and these elements may not be discussed in detailherein with reference to each of FIGS. 1-21. Similarly, all elements maynot be labeled in each of FIGS. 1-21, but reference numerals associatedtherewith may be utilized herein for consistency. Elements, components,and/or features that are discussed herein with reference to one or moreof FIGS. 1-21 may be included in and/or utilized with any of FIGS. 1-21without departing from the scope of the present disclosure.

In general, elements that are likely to be included in a given (i.e., aparticular) embodiment are illustrated in solid lines, while elementsthat are optional to a given embodiment are illustrated in dashed lines.However, elements that are shown in solid lines are not essential to allembodiments, and an element shown in solid lines may be omitted from aparticular embodiment without departing from the scope of the presentdisclosure.

FIG. 1 illustrates an example of an aircraft 700 that includes anelongate composite structure 800 that may be formed using the systemsand methods according to the present disclosure, and FIG. 2 illustratesan example of a wing 740 that may form a portion of aircraft 700 andthat includes composite structure 800. For example, and as illustratedin FIG. 2, elongate composite structure 800 may include and/or be astringer 742 that forms a structural component of wing 740.

Turning now to FIGS. 3-4, FIG. 3 illustrates a system 20 for assemblingelongate composite structure 800 in elevation view, while FIG. 4illustrates system 20 as viewed from above. As illustrated in FIGS. 3-4,system 20 includes a plurality of rigid elongate cure tools 30 with acorresponding plurality of elongate support surfaces 40 configured tosupport a corresponding plurality of elongate charges of compositematerial 80. More specifically, system 20 includes a first rigidelongate cure tool 31 defining a first elongate support surface 41configured to support a first elongate charge of composite material 81and a second rigid elongate cure tool 32 defining a second elongatesupport surface 42 configured to support a second elongate charge ofcomposite material 82. At least a region of second elongate supportsurface 42 faces toward a corresponding region of first elongate supportsurface 41. First elongate charge of composite material 81 also may bereferred to as an FEC 81, and/or second elongate charge of compositematerial 82 also may be referred to as an SEC 82. System 20 may bedescribed as including one or both of FEC 81 and SEC 82.

With continued reference to FIGS. 3-4, system 20 further includes aflexible elongate caul plate 50 extending along first elongate supportsurface 41 and configured to extend between, and spatially separate, thefirst elongate support surface and FEC 81. In some embodiments, flexibleelongate caul plate 50 is configured to spatially separate an entiretyof first elongate support surface 41 from an entirety of FEC 81.Flexible elongate caul plate 50 also may be referred to as a caul plate50. System 20 also includes a vacuum compaction film 60 at leastpartially defining an enclosed volume 64 that includes FEC 81, SEC 82,and caul plate 50. Enclosed volume 64 also may be referred to as aninternal volume 64. System 20 further includes a vacuum source 66configured to apply a vacuum to enclosed volume 64. As illustrated inFIG. 3, system 20 further includes a translation structure 90 configuredto permit, facilitate, and/or produce relative translation between firstrigid elongate cure tool 31 and second rigid elongate cure tool 32.Specifically, translation structure 90 is configured to permit relativetranslation between a first relative orientation, in which FEC 81 isspaced apart from SEC 82, and a second relative orientation, in whichFEC 81 contacts SEC 82. More specifically, translation structure 90 maybe configured to permit the relative translation along a translationaxis, such as a translation axis that is perpendicular to the region ofsecond elongate support surface 42 that faces the corresponding regionof first elongate support surface 41 and/or to the region of the firstelongate support surface that faces the corresponding region of thesecond elongate support surface. This is illustrated in FIGS. 8-19 anddiscussed in more detail herein with reference thereto.

During operation of system 20, flexible elongate caul plate 50 mayextend along and contact elongate charge of composite material 80 toapply a compaction force that is constant, or at least substantiallyconstant, along a length of elongate charge of composite material 80.More specifically, when flexible elongate caul plate 50 is positionedwithin enclosed volume 64, applying a vacuum to enclosed volume 64 maycause vacuum compaction film 60 to urge flexible elongate caul plate 50to bend and/or flex to conform to a shape of elongate charge ofcomposite material 80. By contrast, rigid elongate cure tool 30 may havea shape that does not fully conform to a shape of elongate charge ofcomposite material 80 and/or may have a stiffness that restricts it fromconforming to a shape of the elongate charge of composite material suchthat the rigid elongate cure tool cannot produce a consistent compactionforce across a length of the elongate charge of composite material.Hence, utilizing at least one flexible elongate caul plate 50 positionedwithin enclosed volume 64 may facilitate a more uniform and/or robustjoining of FEC 81 and SEC 82 relative to prior art systems that lackflexible elongate caul plate 50, that do not position the flexibleelongate caul plate within the enclosed volume, and/or that utilizefirst elongate support surface 41 to partially define the enclosedvolume. In some embodiments, system 20 is configured to be utilized inconjunction with a heating assembly 100, such as an oven and/or anautoclave, that defines a heated volume 102 sized to receive the system.In such an embodiment, the heating assembly is configured to heat system20 via heating of the heated volume so as to cure FEC 81 and SEC 82,thereby joining the FEC to the SEC and defining elongate compositestructure 800 from the FEC and the SEC.

Elongate charge of composite material 80 (such as FEC 81 and/or SEC 82)may have any appropriate material and/or conformational construction.For example, in some embodiments, FEC 81 and/or SEC 82 may include acorresponding plurality of plies of composite material, which mayinclude, be, and/or be defined by a plurality of fibers and a resinmaterial. As examples, the plies of composite material may includeand/or be pre-impregnated composite fibers, resin-infused fiberstructures, and/or thermoplastic fiber reinforced materials. As morespecific examples, the resin material may include and/or be a thermosetresin, an epoxy, a thermoset epoxy, an adhesive, a thermoset adhesive, apolymer, and/or a thermoset polymer. As further examples, the pluralityof fibers may include and/or be a plurality of carbon fibers, aplurality of polymeric fibers, a plurality of glass fibers, a pluralityof organic fibers, a plurality of inorganic fibers, and/or a pluralityof metal fibers.

FEC 81 and/or SEC 82 each may be substantially uniform in thicknessand/or material composition along a corresponding length thereof.However, this is not required, and it is within the scope of the presentdisclosure that FEC 81 and/or SEC 82 may have a thickness that variesalong the length thereof. For example, and as illustrated in dashedlines in FIG. 4, FEC 81 and/or SEC 82 may include and/or be a steppedcomposite structure with a number of plies that varies along the lengththereof such that the thickness thereof varies along its length.

As discussed, flexible elongate caul plate 50 is configured to extendalong and contact elongate charge of composite material 80 to apply acompaction force that is constant, or at least substantially constant,along a length of elongate charge of composite material 80.Specifically, flexible elongate caul plate 50 may be configured to morefully conform to a shape of elongate charge of composite material 80when compared to rigid elongate cure tool 30.

For example, first rigid elongate cure tool 31 may have a first curetool stiffness, and/or second rigid elongate cure tool 32 may have asecond cure tool stiffness, and the first cure tool stiffness and/or thesecond cure tool stiffness may be at least a threshold multiple of acaul plate stiffness of flexible elongate caul plate 50. Examples of thethreshold multiple include at least 2, at least 4, at least 6, at least8, at least 10, at least 15, at least 20, at least 40, at least 60, atleast 80, at least 100, at least 250, at least 500, and/or at least1000. In some embodiments, flexible elongate caul plate 50 may not havea constant caul plate stiffness. For example, flexible elongate caulplate 50 may have a stiffness that varies along a length of the caulplate, such as to match a contour of FEC 81 and/or SEC 82 and/or toapply a specific pressure to specific location(s) and/or region(s) alongFEC 81 and/or SEC 82. In such an embodiment, the caul plate stiffnessmay refer to a minimum caul plate stiffness, a maximum caul platestiffness, and/or an average caul plate stiffness.

Additionally or alternatively, in some embodiments, first rigid elongatecure tool 31 and/or second rigid elongate cure tool 32 may not have aconstant cure tool stiffness. For example, the first cure tool stiffnessmay vary along a length of first rigid elongate cure tool 31, and/or thesecond cure tool stiffness may vary along a length of second rigidelongate cure tool 32. In such an embodiment, the first cure toolstiffness and/or the second cure tool stiffness may refer to a minimumcure tool stiffness, a maximum cure tool stiffness, and/or an averagecure tool stiffness.

In some embodiments, and as schematically illustrated in FIG. 4, firstelongate support surface 41 and/or second elongate support surface 42may define a first planar, or at least substantially planar, region 44,a second planar, or at least substantially planar, region 46, and asupport surface transition region 45, which transitions between firstplanar, or at least substantially planar, region 44 and second planar,or at least substantially planar, region 46. In such an embodiment,flexible elongate caul plate 50 may extend across at least a fraction offirst planar, or at least substantially planar, region 44, secondplanar, or at least substantially planar, region 46, and support surfacetransition region 45. Stated differently, in an embodiment in whichfirst elongate support surface 41 and/or second elongate support surface42 is not planar, or at least substantially planar, flexible elongatecaul plate 50 may be positioned between the rigid elongate cure tool andelongate charge of composite material 80 to better conform to theelongate charge of composite material.

Additionally or alternatively, elongate charge of composite material 80may not have a constant thickness along its length. For example, in anembodiment in which FEC 81 and/or SEC 82 has a thickness and/or a numberof plies that varies along its length, the FEC and/or the SEC may notreceive a consistent compaction force from a prior art rigid elongatecure tool that is not utilized in conjunction with flexible elongatecaul plate 50, as disclosed herein.

Flexible elongate caul plate 50 may be formed from any appropriatematerial, such as a flexible material, a resilient material, a polymericmaterial, a composite material, and/or the composite material utilizedto form and/or define elongate charge of composite material 80. As amore specific example, FEC 81 may be formed from an FEC material, andflexible elongate caul plate 50 may be formed from the FEC material.Additionally or alternatively, flexible elongate caul plate 50 may beformed from a plurality of layered plies of composite material. In suchan embodiment, flexible elongate caul plate 50 may be formed from anyappropriate number of layered plies of composite material, examples ofwhich include at least 2, at least 3, at least 4, at least 5, at least6, at least 8, at least 10, at most 20, at most 18, at most 16, at most14, at most 12, at most 10, at most 8, and/or at most 6 layered plies ofcomposite material.

Vacuum compaction film 60 may include and/or be any appropriate filmand/or material appropriate for drawing a vacuum therein, examples ofwhich include a polymeric film, a polymeric sheet, a nylon sheet, aflexible material, a compliant material, a vacuum bag, afluid-impermeable material, and/or an at least substantiallyfluid-impermeable material. Vacuum source 66 may include and/or be anyappropriate apparatus for evacuating enclosed volume 64, examples ofwhich include a vacuum pump, a blower, and/or a vacuum blower. Asillustrated in FIGS. 3-4, a region of vacuum compaction film 60 extendsbetween, and spatially separates, caul plate 50 and first elongatesupport surface 41.

In some embodiments, system 20 further may include a breather film 68and/or a release film 69 extending between, and spatially separating,vacuum compaction film 60 and FEC 81, SEC 82, and/or flexible elongatecaul plate 50. As used herein, release film 69 also may be referred toas a peel ply 69. As examples, breather film 68 may include and/or be aporous breather film, a woven breather film, a polyester breather film,and/or a vacuum distributing breather film. As further examples, releasefilm 69 may include and/or be a porous release film, a low surfaceenergy release film, and/or a perfluoro tetrafluoroethylene (PTFE)release film. In an embodiment that includes both the breather film andthe release film, the release film may extend between, and spatiallyseparate, the breather film and FEC 81, SEC 82, and/or flexible elongatecaul plate 50. Additionally or alternatively, vacuum compaction film 60may include a coating configured to facilitate removal of vacuumcompaction film 60 from FEC 81, SEC 82, and/or flexible elongate caulplate 50.

As illustrated in FIG. 3, system 20 may include at least one sealingstructure 70 for forming a fluid seal between vacuum compaction film 60and another component of system 20. For example, sealing structure 70may be utilized to form the fluid seal between vacuum compaction film 60and first rigid elongate cure tool 31 and/or second rigid elongate curetool 32. It is within the scope of the present disclosure that system 20may include any suitable number of sealing structures 70. As an example,and in some embodiments, system 20 may include a first sealing structure71 that operatively attaches, and forms a fluid seal between, a firstedge 12 of vacuum compaction film 60 and second rigid elongate cure tool32, and a second sealing structure 72 that operatively attaches, andforms a fluid seal between, a second edge 14 of the vacuum compactionfilm and the second rigid elongate cure tool. Each sealing structure 70may include and/or be any appropriate structure and/or material forforming a fluid seal, examples of which include an adhesive, a tape, anadhesive tape, a removable adhesive, a sealant tape, and a gel.

As used herein, first edge 12 and second edge 14 of vacuum compactionfilm 60 may (respectively) refer to any appropriate portions of thevacuum compaction film. For example, first edge 12 of vacuum compactionfilm 60 may be opposed to second edge 14 of the vacuum compaction film.Stated differently, first edge 12 and second edge 14 of vacuumcompaction film 60 may be located on or near opposite sides and/or edgesof the vacuum compaction film. As another example, first edge 12 and/orsecond edge 14 generally refer to portions of vacuum compaction film 60that are at, or near, an edge of the vacuum compaction film. However,this is not required, and it is additionally within the scope of thepresent disclosure that first edge 12 and/or second edge 14 of vacuumcompaction film 60 may respectively refer to portions of the vacuumcompaction film that are not proximal to an edge of the vacuumcompaction film. In such an embodiment, vacuum compaction film 60 may bedescribed as being oversized and/or larger than necessary for thecompaction of elongate composite structure 800.

As schematically illustrated in FIGS. 3-4, system 20 may include aplurality of vacuum compaction films 60. For example, in someembodiments, system 20 includes a first vacuum compaction film 61 and asecond vacuum compaction film 62. In such an embodiment, system 20 mayinclude sealing structures 70 that seal each vacuum compaction film 60to first rigid elongate cure tool 31 and/or to second rigid elongatecure tool 32. For example, system 20 may include first sealing structure71 that operatively attaches, and forms a fluid seal between, first edge12 of first vacuum compaction film 61 and second rigid elongate curetool 32, and further may include second sealing structure 72 thatoperatively attaches, and forms a fluid seal between, a first edge 16 ofsecond vacuum compaction film 62 and the second rigid elongate curetool. Such an embodiment still further may include a third sealingstructure 73 that operatively attaches, and forms a fluid seal between,second edge 14 of first vacuum compaction film 61, a second edge 18 ofsecond vacuum compaction film 62, and/or second rigid elongate cure tool32. In such an embodiment, second elongate support surface 42, firstvacuum compaction film 61, and second vacuum compaction film 62 may bedescribed as collectively forming and/or defining enclosed volume 64.

As schematically illustrated in FIGS. 3-4, system 20 may include aplurality of flexible elongate caul plates 50. For example, flexibleelongate caul plate 50 that extends along first elongate support surface41 may be a first flexible elongate caul plate 51, and system 20 furthermay include a second flexible elongate caul plate 52 extending alongsecond elongate support surface 42 and configured to extend between, andspatially separate, the second elongate support surface and SEC 82. Insome embodiments of systems 20 that include second flexible elongatecaul plate 52, the region of vacuum compaction film 60 that extendsbetween, and spatially separates, first flexible elongate caul plate 51and first elongate support surface 41 is a first region of the vacuumcompaction film, and the vacuum compaction film further may include asecond region that extends between, and spatially separates, secondflexible elongate caul plate 52 and second elongate support surface 42.In other embodiments of system 20 that include second flexible elongatecaul plate 52, vacuum compaction film 60 may not include a region thatextends between, and spatially separates, the second flexible elongatecaul plate and second elongate support surface 42. In such embodiments,second flexible elongate caul plate 52 may be referred to as a spacercaul and/or a shim caul, and/or may be positioned within enclosed volume64.

In an embodiment of system 20 that includes first flexible elongate caulplate 51 and second flexible elongate caul plate 52, sealing structure70 may operatively attach, and form a fluid seal between, one of firstrigid elongate cure tool 31 and second rigid elongate cure tool 32 andeach of first edge 12 and second edge 14 of vacuum compaction film 60.Stated differently, vacuum compaction film 60 may extend between firstelongate support surface 41 and first flexible elongate caul plate 51and between second elongate support surface 42 and second flexibleelongate caul plate 52, thereby enclosing each of FEC 81, SEC 82, firstflexible elongate caul plate 51, and second flexible elongate caul plate52 and forming a fluid seal with either of first rigid elongate curetool 31 and second rigid elongate cure tool 32 via sealing structure 70.Hence, vacuum compaction film 60 may completely, or at leastsubstantially completely, define enclosed volume 64.

It is additionally within the scope of the present disclosure that, inan embodiment of system 20 that includes first flexible elongate caulplate 51 and second flexible elongate caul plate 52, system 20 includesfirst vacuum compaction film 61 and second vacuum compaction film 62. Insuch an embodiment, system 20 may include first sealing structure 71that operatively attaches, and forms a fluid seal between, first rigidelongate cure tool 31 and both first edge 12 of first vacuum compactionfilm 61 and first edge 16 of second vacuum compaction film 62. In thisembodiment, system 20 may further include second sealing structure 72that operatively attaches, and forms a fluid seal between, secondelongate cure tool 32 and both second edge 14 of first vacuum compactionfilm 61 and second edge 18 of second vacuum compaction film 62. Stateddifferently, first vacuum compaction film 61 may extend between firstelongate support surface 41 and first flexible elongate caul plate 51and also between second elongate support surface 42 and second flexibleelongate caul plate 52. In addition, second vacuum compaction film 62may be sealed to both first rigid elongate cure tool 31 and second rigidelongate cure tool 32 such that the first vacuum compaction film and thesecond vacuum compaction film collectively define enclosed volume 64.

FIGS. 5-6 schematically illustrate examples of configurations of systems20, of rigid elongate cure tools 30, of flexible elongate caul plates50, and/or of elongate charges of composite material 80 that are withinthe scope of the present disclosure. For example, and as illustrated inFIG. 5, FEC 81 may extend across two faces of first rigid elongate curetool 31, and/or SEC 82 may extend across two faces of second rigidelongate cure tool 32. Alternatively, and as illustrated in FIG. 6, FEC81 may extend across three faces of first rigid elongate cure tool 31,and/or SEC 82 may extend across three faces of second rigid elongatecure tool 32. In each case, each flexible elongate caul plate 50generally extends between each corresponding rigid elongate cure tool 30and the corresponding elongate charge of composite material 80. Asfurther illustrated in FIGS. 5-6, FEC 81 and SEC 82 may define one ormore arcuate transition regions 85 therebetween, and elongate compositestructure 800 may further include a radius filler 84 positioned withineach of one or more of arcuate transition regions 85. Additionally oralternatively, FEC 81 and SEC 82 together may define one or more exposedsurfaces, and elongate composite structure 800 may include a base charge86 positioned on each of one or more of the exposed surfaces. Radiusfiller 84 and/or base charge 86, when present, may be examples ofelongate charges of composite material 80, and may be formed from thesame material as either or both of FEC 81 and SEC 82. As furtherillustrated in FIG. 5, system 20 also may include peel ply 69 positionedon base charge 86, and may include a peel ply caul plate 88 positionedon peel ply 69. Peel ply caul plate 88 may include and/or be anyappropriate material for applying a constant, or at least substantiallyconstant, compaction force to peel ply 69 and/or base charge 86. Forexample, peel ply caul plate 88 may have a peel ply caul plate stiffnessthat is greater than, less than, substantially equal to, or equal to thecaul plate stiffness of first flexible elongate caul plate 51 and/or ofsecond flexible elongate caul plate 52.

FIGS. 7 and 20 schematically provide flowcharts that representillustrative, non-exclusive examples of methods according to the presentdisclosure. In FIGS. 7 and 20, some steps are illustrated in dashedboxes indicating that such steps may be optional or may correspond to anoptional version of methods according to the present disclosure. Thatsaid, not all methods according to the present disclosure are requiredto include the steps illustrated in solid boxes. The methods and stepsillustrated in FIGS. 7 and 20 are not limiting and other methods andsteps are within the scope of the present disclosure, including methodshaving greater than or fewer than the number of steps illustrated, asunderstood from the discussions herein.

FIG. 7 provides a flowchart of methods 200 of assembling an elongatecomposite structure, and FIGS. 8-19 schematically illustrate portionsand/or steps of methods 200. FIGS. 8-19 illustrate flexible elongatecharges 51 and 52 that contact only a single face of corresponding rigidelongate cure tools 50. However, it is within the scope of the presentdisclosure that methods 200 of FIGS. 7-19 may include, utilize, and/orbe utilized to assemble elongate composite structures that contact two,three, or more faces of corresponding rigid elongate cure tools 50.Examples of such elongate composite structures are illustrated in FIGS.5-6 and discussed herein with reference thereto.

As seen in FIG. 7, methods 200 of assembling an elongate compositestructure (such as elongate composite structure 800) include positioningat 210 a vacuum compaction film (such as vacuum compaction film 60) on afirst elongate support surface of a first rigid elongate cure tool (suchas first elongate support surface 41 of first rigid elongate cure tool31), and positioning at 220 a flexible elongate caul plate (such asflexible elongate caul plate 50) on the first elongate support surfacesuch that the vacuum compaction film extends between, and spatiallyseparates, the flexible elongate caul plate and the first elongatesupport surface. As an example, FIG. 8 schematically illustrates thepositioning at 210, with vacuum compaction film 60 being illustrated onfirst elongate support surface 41 of first rigid elongate cure tool 31,and FIG. 9 schematically illustrates the positioning at 220, withflexible elongate caul plate 50 being illustrated on the first elongatesupport surface.

Methods 200 further include positioning at 250 a first elongate charge(FEC) of composite material (such as FEC 81) on the first elongatesupport surface such that the vacuum compaction film and the flexibleelongate caul plate extend between, and spatially separate, the FEC andthe first elongate support surface. Methods 200 also include positioningat 260 a second elongate charge (SEC) of composite material (such as SEC82) on a second elongate support surface of a second rigid elongate curetool (such as second elongate support surface 42 of second rigidelongate cure tool 32). FIG. 10 schematically illustrates thepositioning at 250 of FEC 81 on first elongate support surface 41 andthe positioning at 260 of SEC 82 on second elongate support surface 42of second rigid elongate cure tool 32. As indicated in FIG. 7, and asschematically illustrated in FIG. 11, methods 200 further includecontacting at 270 a region of the FEC with a region of the SEC to definean interface region 83 between the FEC and the SEC.

In some embodiments, the contacting at 270 may result in the FEC and theSEC defining an arcuate transition region therebetween. In such anembodiment, methods 200 may include, subsequent to the contacting at 270and prior to the sealing at 320, positioning at 280 a radius filler(such as radius filler 84) within the arcuate transition region.Additionally or alternatively, subsequent to the contacting at 270, theFEC and the SEC together may define an exposed surface, and methods 200may include, prior to the sealing at 320, positioning at 290 a basecharge (such as base charge 86) on the exposed surface. Examples ofsystems 20 that include radius filler 84 and/or base charge 86 areillustrated in FIGS. 5-6. With continued reference to FIG. 7, in anembodiment of methods 200 that includes the positioning at 290 the basecharge, the methods also may include positioning at 300 a peel ply (suchas peel ply 69) on the base charge, and further may include, subsequentto the positioning at 300, positioning at 310 a peel ply caul plate(such as peel ply caul plate 88) on peel ply 69.

Methods 200 further include sealing at 320 the vacuum compaction filmagainst at least one of the first elongate support surface and thesecond elongate support surface to at least partially define an enclosedvolume (such as enclosed volume 64) that includes the FEC, the SEC, andthe flexible elongate caul plate. Methods 200 subsequently includeevacuating at 330 enclosed volume 64 to compact the FEC and the SEC.More specifically, the evacuating at 330 may include pressing the FECand the SEC against one another, thereby generating an elongatecomposite assembly that includes the FEC, the SEC, the vacuum compactionfilm, the first elongate cure tool, and the second elongate cure tool.

Methods 200 further include heating at 340 the elongate compositeassembly to cure the FEC and the SEC, to join the FEC to the SEC withinthe interface region, and/or to define the elongate composite structurefrom the FEC and the SEC. Methods 200 additionally may include,subsequent to the heating at 340, separating at 350 the first rigidelongate cure tool, the second rigid elongate cure tool, and the vacuumcompaction film from the elongate composite structure.

The sealing at 320 may be performed in any appropriate manner. Forexample, and as schematically illustrated in FIG. 12, the sealing at 320may include sealing first edge 12 of vacuum compaction film 60 againstsecond rigid elongate cure tool 32 (such as with first sealing structure71) and sealing second edge 14 of the vacuum compaction film against thesecond rigid elongate cure tool (such as with second sealing structure72). In such an embodiment, the vacuum compaction film and the secondelongate support surface together define enclosed volume 64.

However, this is not required, and it is additionally within the scopeof the present disclosure that the sealing 320 include utilizing aplurality of vacuum compaction films. For example, and as schematicallyillustrated in FIG. 13, system 20 may include a first vacuum compactionfilm (such as first vacuum compaction film 61) and a second vacuumcompaction film (such as second vacuum compaction film 62). In such anembodiment, the sealing at 320 may include sealing first edge 12 of thefirst vacuum compaction film against second rigid elongate cure tool 32(such as with first sealing structure 71), sealing second edge 14 of thefirst vacuum compaction film against first rigid elongate cure tool 31(such as with third sealing structure 73), sealing first edge 16 of thesecond vacuum compaction film against the second rigid elongate curetool (such as with second sealing structure 72), and sealing second edge18 of the second vacuum compaction film against the first rigid elongatecure tool (such as with the third sealing structure). In such anembodiment, the first vacuum compaction film, the second vacuumcompaction film, and the second elongate support surface together defineenclosed volume 64.

FIGS. 8-13 generally illustrate steps of methods 200 performed in asystem 20 that includes a single flexible elongate caul plate 50.However, this is not required, and it is additionally within the scopeof the present disclosure that methods 200 be performed in a system thatincludes a plurality of elongate flexible caul plates. As an example,FIGS. 14-19 generally illustrate steps of methods 200 performed in asystem 20 that includes a first flexible elongate caul plate 51 and asecond flexible elongate caul plate 52. However, it is within the scopeof the present disclosure that first flexible elongate caul plate 51 orsecond flexible elongate caul plate 52 may be omitted from the steps ofmethods 200, such as are illustrated in FIGS. 14-19, without departingfrom the scope of the present disclosure.

Specifically, and with continued reference to FIG. 7, methods 200 mayinclude, prior to the positioning at 260 the SEC, positioning at 230 ofthe vacuum compaction film on the second elongate support surface andpositioning at 240 of the second flexible elongate caul plate on thesecond elongate support surface such that the second vacuum compactionfilm extends between, and spatially separates, the second flexibleelongate caul plate and the second elongate support surface. As anexample, FIG. 14 schematically illustrates the positioning at 210 ofvacuum compaction film 60 on first elongate support surface 41 and thepositioning at 230 of vacuum compaction film 60 on second elongatesupport surface 42. FIG. 15 schematically illustrates the positioning at220 of first elongate caul plate 51 and the positioning at 240 of secondelongate caul plate 52. In such an embodiment, and as schematicallyillustrated in FIG. 16, the positioning at 260 of SEC 82 includespositioning the SEC such that both vacuum compaction film 60 and secondelongate caul plate 52 extend between, and spatially separate, the SECand second elongate support surface 42. FIG. 17 schematicallyillustrates the contacting at 270 a region of FEC 81 with a region ofSEC 82 to define interface region 83.

In an embodiment of methods 200 that includes utilizing two flexibleelongate caul plates, the sealing at 320 may be performed in anyappropriate manner. As an example, and as schematically illustrated inFIG. 18, the sealing 320 may include sealing both first edge 12 secondedge 14 of vacuum compaction film 60 against either first elongatesupport surface 41 or second elongate support surface 42.

Alternatively, an embodiment of methods 200 may include utilizing twoflexible elongate caul plates and two vacuum compaction films. As anexample, and as schematically illustrated in FIG. 19, the sealing at 320may include sealing first edge 12 of first vacuum compaction film 61 andfirst edge 16 of second vacuum compaction film 62 against first elongatesupport surface 41 (such as with first sealing structure 71) and sealingsecond edge 14 of the first vacuum compaction film and second edge 18 ofthe second vacuum compaction film against second elongate supportsurface 42 (such as with second sealing structure 72). In such anembodiment, the first vacuum compaction film and the second vacuumcompaction film together define enclosed volume 64.

Turning now to FIGS. 20-21, embodiments of the present disclosure may bedescribed in the context of an aircraft manufacturing and service method900 as shown in FIG. 20 and an aircraft 700 as shown in FIG. 21. Duringpre-production, exemplary method 900 may include specification anddesign 905 of the aircraft 700 and material procurement 910. Duringproduction, component and subassembly manufacturing 915 and systemintegration 920 of the aircraft 700 takes place. Thereafter, theaircraft 700 may go through certification and delivery 925 in order tobe placed in service 930. While in service, the aircraft 700 isscheduled for routine maintenance and service 935 (which may alsoinclude modification, reconfiguration, refurbishment, and so on).

Each of the processes of method 900 may be performed or carried out by asystem integrator, a third party, and/or an operator (e.g., a customer).For the purposes of this description, a system integrator may includewithout limitation any number of aircraft manufacturers and major-systemsubcontractors; a third party may include without limitation any numberof venders, subcontractors, and suppliers; and an operator may be anairline, leasing company, military entity, service organization, and soon.

As shown in FIG. 21, the aircraft 700 produced by exemplary method 900may include an airframe 710 with a plurality of systems 712 and aninterior 714. Examples of high-level systems 712 include one or more ofa propulsion system 715, an electrical system 716, a hydraulic system717, and an environmental system 718. Any number of other systems alsomay be included. Although an aerospace example is shown, the principlesof the inventions disclosed herein may be applied to other industries,such as the automotive industry.

Apparatus and methods disclosed herein may be employed during any one ormore of the stages of the production and service method 900. Forexample, components or subassemblies corresponding to production process915 may be fabricated or manufactured in a manner similar to componentsor subassemblies produced while the aircraft 700 is in service. Also,one or more apparatus embodiments, method embodiments, or a combinationthereof may be utilized during the production stages 915 and 920, forexample, by substantially expediting assembly of or reducing the cost ofan aircraft 700. Similarly, one or more of apparatus embodiments, methodembodiments, or a combination thereof may be utilized while the aircraft700 is in service, for example and without limitation, to maintenanceand service 935.

Illustrative, non-exclusive examples of inventive subject matteraccording to the present disclosure are described in the followingenumerated paragraphs:

A1. A system for assembling an elongate composite structure, the systemcomprising:

a first rigid elongate cure tool defining a first elongate supportsurface configured to support a first elongate charge of compositematerial (FEC);

a flexible elongate caul plate extending along the first elongatesupport surface and configured to extend between, and spatiallyseparate, the first elongate support surface and the FEC;

a second rigid elongate cure tool defining a second elongate supportsurface configured to support a second elongate charge of compositematerial (SEC), wherein at least a region of the second elongate supportsurface faces toward a corresponding region of the first elongatesupport surface;

a translation structure configured to permit relative translationbetween the first rigid elongate cure tool and the second rigid elongatecure tool from a first relative orientation, in which the FEC isspaced-apart from the SEC, and a second relative orientation, in whichthe FEC contacts the SEC;

a vacuum compaction film at least partially defining an enclosed volumethat includes the FEC, the SEC, and the flexible elongate caul plate,wherein a region of the vacuum compaction film extends between, andspatially separates, the flexible elongate caul plate and the firstelongate support surface; and

a vacuum source configured to apply a vacuum to the enclosed volume.

A2. The system of paragraph A1, wherein the system further includes:

(i) a first sealing structure that operatively attaches, and forms afluid seal between, a first edge of the vacuum compaction film and thesecond rigid elongate cure tool; and

(ii) a second sealing structure that operatively attaches, and forms afluid seal between, a second edge of the vacuum compaction film and thesecond rigid elongate cure tool.

A3. The system of paragraph A2, wherein the second elongate supportsurface and the vacuum compaction film together define the enclosedvolume.

A4. The system of paragraph A2, wherein the first edge of the vacuumcompaction film is opposed to the second edge of the vacuum compactionfilm.

A5. The system of paragraph A1, wherein the vacuum compaction film is afirst vacuum compaction film, and further wherein the system includes:

(i) a second vacuum compaction film at least partially defining theenclosed volume;

(ii) a first sealing structure that operatively attaches, and forms afluid seal between, a first edge of the first vacuum compaction film andthe second rigid elongate cure tool;

(iii) a second sealing structure that operatively attaches, and forms afluid seal between, a first edge of the second vacuum compaction filmand the second rigid elongate cure tool; and

(iv) a third sealing structure that operatively attaches, and forms afluid seal between, the first rigid elongate cure tool and both a secondedge of the first vacuum compaction film and a second edge of the secondvacuum compaction film.

A6. The system of paragraph A5, wherein the second elongate supportsurface, the first vacuum compaction film, and the second vacuumcompaction film together define the enclosed volume.

A7. The system of any of paragraphs A5-A6, wherein the first edge of thefirst vacuum compaction film is opposed to the second edge of the firstvacuum compaction film.

A8. The system of any of paragraphs A5-A7, wherein the first edge of thesecond vacuum compaction film is opposed to the second edge of thesecond vacuum compaction film.

A9. The system of any of paragraphs A1-A8, wherein the system furtherincludes a spacer caul extending along the second elongate supportsurface and configured to extend between, and spatially separate, thesecond elongate support surface and the SEC.

A10. The system of paragraph A9, wherein the spacer caul is positionedwithin the enclosed volume.

A11. The system of paragraph A1, wherein the flexible elongate caulplate is a first flexible elongate caul plate, and further wherein thesystem includes a second flexible elongate caul plate extending alongthe second elongate support surface and configured to extend between,and spatially separate, the second elongate support surface and the SEC,wherein the region of the vacuum compaction film is a first region ofthe vacuum compaction film, and further wherein a second region of thevacuum compaction film extends between, and spatially separates, thesecond flexible elongate caul plate and the second elongate supportsurface.

A12. The system of paragraph A11, wherein the system further includes:

a sealing structure that operatively attaches, and forms a fluid sealbetween, one of the first rigid elongate cure tool and the second rigidelongate cure tool and both a first edge of the vacuum compaction filmand a second edge of the vacuum compaction film.

A13. The system of paragraph A12, wherein the vacuum compaction filmcompletely, or at least substantially completely, defines the enclosedvolume.

A14. The system of any of paragraphs A12-A13, wherein the first edge ofthe vacuum compaction film is opposed to the second edge of the vacuumcompaction film.

A15. The system of paragraph A11, wherein the vacuum compaction film isa first vacuum compaction film, and wherein the system further includes:

a second vacuum compaction film at least partially defining the enclosedvolume;

a first sealing structure that operatively attaches, and forms a fluidseal between, the first rigid elongate cure tool and both a first edgeof the first vacuum compaction film and a first edge of the secondvacuum compaction film; and

a second sealing structure that operatively attaches, and forms a fluidseal between, the second rigid elongate cure tool and both a second edgeof the first vacuum compaction film and a second edge of the secondvacuum compaction film.

A16. The system of paragraph A15, wherein the first vacuum compactionfilm and the second vacuum compaction film together define the enclosedvolume.

A17. The system of any of paragraphs A15-A16, wherein the first edge ofthe first vacuum compaction film is opposed to the second edge of thefirst vacuum compaction film.

A18. The system of any of paragraphs A15-A17, wherein the first edge ofthe second vacuum compaction film is opposed to the second edge of thesecond vacuum compaction film.

A19. The system of any of paragraphs A1-A18, wherein a first cure toolstiffness of the first rigid elongate cure tool is at least a thresholdmultiple of a caul plate stiffness of the flexible elongate caul plate,optionally wherein the threshold multiple is at least 2, at least 4, atleast 6, at least 8, at least 10, at least 15, at least 20, at least 40,at least 60, at least 80, at least 100, at least 250, at least 500,and/or at least 1000.

A20. The system of any of paragraphs A1-A19, wherein a second cure toolstiffness of the second rigid elongate cure tool is at least a thresholdmultiple of a/the caul plate stiffness of the flexible elongate caulplate, optionally wherein the threshold multiple is at least 2, at least4, at least 6, at least 8, at least 10, at least 15, at least 20, atleast 40, at least 60, at least 80, at least 100, at least 250, at least500, and/or at least 1000.

A21. The system of any of paragraphs A1-A20, wherein the first elongatesupport surface defines a first planar, or at least substantiallyplanar, region, a second planar, or at least substantially planar,region, and a first elongate support surface transition region, whichtransitions between the first planar, or at least substantially planar,region and the second planar, or at least substantially planar, region.

A22. The system of paragraph A21, wherein the flexible elongate caulplate extends across at least a fraction of the first planar, or atleast substantially planar, region, the second planar, or at leastsubstantially planar, region, and the first elongate support surfacetransition region.

A23. The system of any of paragraphs A1-A22, wherein the system includesat least one, and optionally both, of the FEC and the SEC.

A24. The system of any of paragraphs A1-A23, wherein at least one, andoptionally both, of the FEC and the SEC includes a correspondingplurality of plies of composite material.

A25. The system of paragraph A24, wherein the plurality of plies ofcomposite material includes, is, or is defined by, a plurality of fibersand a resin material.

A26. The system of paragraph A25, wherein the resin material includes atleast one of a thermoset resin, an epoxy, a thermoset epoxy, anadhesive, a thermoset adhesive, a polymer, and a thermoset polymer.

A27. The system of any of paragraphs A25-A26, wherein the plurality offibers includes at least one of a plurality of carbon fibers, aplurality of polymeric fibers, a plurality of glass fibers, a pluralityof organic fibers, a plurality of inorganic fibers, and a plurality ofmetallic fibers.

A28. The system of any of paragraphs A1-A27, wherein the vacuumcompaction film includes, or is, at least one of a polymeric film, apolymeric sheet, a nylon sheet, flexible, compliant, a vacuum bag,fluid-impermeable, and at least substantially fluid-impermeable.

A29. The system of any of paragraphs A1-A28, wherein the FEC is formedfrom an FEC material, and further wherein the flexible elongate caulplate is formed from the FEC material.

A30. The system of any of paragraphs A1-A29, wherein the flexibleelongate caul plate is formed from a plurality of layered plies ofcomposite material.

A31. The system of paragraph A30, wherein the plurality of plies ofcomposite material includes at least one of:

(i) at least 2, at least 3, at least 4, at least 6, at least 8, or atleast 10 layered plies of composite material; and

(ii) at most 20, at most 18, at most 16, at most 14, at most 12, at most10, at most 8, or at most 6 layered plies of composite material.

A32. The system of any of paragraphs A1-A31, wherein the flexibleelongate caul plate is formed from at least one of a flexible material,a resilient material, a polymeric material, and a/the compositematerial.

A33. The system of any of paragraphs A1-A32, wherein the flexibleelongate caul plate is configured to spatially separate an entirety ofthe first elongate support surface from an entirety of the FEC.

A34. The system of any of paragraphs A1-A33, wherein the system furtherincludes a breather film extending between, and spatially separating,the vacuum compaction film and at least one of the FEC, the SEC, and theflexible elongate caul plate.

A35. The system of paragraph A34, wherein the breather film includes atleast one of a porous breather film, a woven breather film, a polyesterbreather film, and a vacuum distributing breather film.

A36. The system of any of paragraphs A1-A35, wherein the system furtherincludes a release film extending between, and spatially separating thevacuum compaction film and at least one of the FEC, the SEC, and theflexible elongate caul plate.

A37. The system of paragraph A36, wherein the release film furtherextends between, and spatially separates, a/the breather film and atleast one of the FEC, the SEC, and the flexible elongate caul plate.

A38. The system of any of paragraphs A36-A37, wherein the release filmincludes at least one of a porous release film, a low surface energyrelease film, and a perfluoro tetrafluoroethylene (PTFE) release film.

A39. The system of any of paragraphs A1-A38, wherein the translationstructure is configured to permit the relative translation along atranslation axis, optionally wherein the translation axis isperpendicular to at least one, and optionally both, of the region of thesecond elongate support surface and the corresponding region of thefirst elongate support surface.

A40. The system of any of paragraphs A1-A39, wherein the vacuum sourceincludes at least one of a vacuum pump, a blower, and a vacuum blower.

A41. The system of any of paragraphs A1-A40 in combination with aheating assembly that defines a heated volume, wherein the heated volumeis sized to receive the system, and further wherein the heating assemblyis configured to heat the system, via heating of the heated volume, tocure the FEC and the SEC, to join the FEC to the SEC, and to define theelongate composite structure from the FEC and the SEC.

A42. The system of paragraph A41, wherein the heating assembly includesat least one of an oven and an autoclave.

B1. A method of assembling an elongate composite structure, the methodcomprising:

positioning a vacuum compaction film on a first elongate support surfaceof a first rigid elongate cure tool;

positioning a flexible elongate caul plate on the first elongate supportsurface such that the vacuum compaction film extends between, andspatially separates, the flexible elongate caul plate and the firstelongate support surface;

positioning a first elongate charge of composite material (FEC) on thefirst elongate support surface such that the vacuum compaction film andthe flexible elongate caul plate extend between, and spatially separate,the FEC and the first elongate support surface;

positioning a second elongate charge of composite material (SEC) on asecond elongate support surface of a second rigid elongate cure tool;

contacting a region of the FEC with a region of the SEC to define aninterface region between the FEC and the SEC;

sealing the vacuum compaction film against at least one of the firstelongate support surface and the second elongate support surface to atleast partially define an enclosed volume that includes the FEC, theSEC, and the flexible elongate caul plate;

evacuating the enclosed volume to compact the FEC and the SEC, to pressthe FEC and the SEC against one another, and to generate an elongatecomposite assembly that includes the FEC, the SEC, the vacuum compactionfilm, the first elongate cure tool, and the second elongate cure tool;and

heating the elongate composite assembly to cure the FEC and the SEC, tojoin the FEC to the SEC within the interface region, and to define theelongate composite structure from the FEC and the SEC.

B2. The method of paragraph B1, wherein the sealing the vacuumcompaction film includes sealing a first edge of the vacuum compactionfilm against the second rigid elongate cure tool and sealing a secondedge of the vacuum compaction film against the second rigid elongatecure tool such that the vacuum compaction film and the second elongatesupport surface together define the enclosed volume.

B3. The method of paragraph B1, wherein the vacuum compaction film is afirst vacuum compaction film, wherein the sealing the first vacuumcompaction film includes sealing a first edge of the first vacuumcompaction film against the second rigid elongate cure tool and sealinga second edge of the first vacuum compaction film against the firstrigid elongate cure tool, and further wherein the method includessealing a first edge of a second vacuum compaction film against thesecond rigid elongate cure tool and sealing a second edge of the secondvacuum compaction film against the first rigid elongate cure tool suchthat the first vacuum compaction film, the second vacuum compactionfilm, and the second elongate support surface together define theenclosed volume.

B4. The method of paragraph B1, wherein the flexible elongate caul plateis a first flexible elongate caul plate, and further wherein the methodincludes:

prior to the positioning the SEC, positioning the vacuum compaction filmon the second elongate support surface; and

prior to the positioning the SEC and subsequent to the positioning thevacuum compaction film on the second elongate support surface,positioning a second flexible elongate caul plate on the second elongatesupport surface such that the vacuum compaction film extends between,and spatially separates, the second flexible elongate caul plate and thesecond elongate support surface, wherein the positioning the SECincludes positioning the SEC such that both the vacuum compaction filmand the second elongate caul plate extend between, and spatiallyseparate, the SEC and the second elongate support surface.

B5. The method of paragraph B4, wherein the sealing the vacuumcompaction film includes sealing both a first edge of the vacuumcompaction film and a second edge of the vacuum compaction film againsta selected one of the first elongate support surface and the secondelongate support surface.

B6. The method of paragraph B4, wherein the vacuum compaction film is afirst vacuum compaction film, and further wherein:

the sealing the first vacuum compaction film includes sealing a firstedge of the first vacuum compaction film against the first elongatesupport surface and sealing a second edge of the first vacuum compactionfilm against the second elongate support surface; and

the method further includes sealing a first edge of a second vacuumcompaction film against the first elongate support surface and sealing asecond edge of the second vacuum compaction film against the secondelongate support surface such that the first vacuum compaction film andthe second vacuum compaction film together define the enclosed volume.

B7. The method of any of paragraphs B1-B6, wherein, subsequent to thecontacting, the FEC and the SEC define an arcuate transition regiontherebetween, and further wherein, subsequent to the contacting andprior to the sealing, the method further includes positioning a radiusfiller within the arcuate transition region.

B8. The method of any of paragraphs B1-B7, wherein, subsequent to thecontacting, the FEC and the SEC together define an exposed surface, andfurther wherein, prior to the sealing, the method further includespositioning a base charge on the exposed surface.

B9. The method of paragraph B8, wherein, subsequent to the positioningthe base charge, the method further includes positioning a peel ply onthe base charge.

B10. The method of paragraph B9, wherein, subsequent to the positioningthe peel ply, the method further includes positioning a peel ply caulplate on the peel ply.

B11. The method of any of paragraphs B1-B10, wherein, subsequent to theheating, the method further includes separating the first rigid elongatecure tool, the second rigid elongate cure tool, and the vacuumcompaction film from the elongate composite structure.

As used herein, the terms “selective” and “selectively,” when modifyingan action, movement, configuration, or other activity of one or morecomponents or characteristics of an apparatus, mean that the specificaction, movement, configuration, or other activity is a direct orindirect result of user manipulation of an aspect of, or one or morecomponents of, the apparatus.

As used herein, the terms “adapted” and “configured” mean that theelement, component, or other subject matter is designed and/or intendedto perform a given function. Thus, the use of the terms “adapted” and“configured” should not be construed to mean that a given element,component, or other subject matter is simply “capable of” performing agiven function but that the element, component, and/or other subjectmatter is specifically selected, created, implemented, utilized,programmed, and/or designed for the purpose of performing the function.It is also within the scope of the present disclosure that elements,components, and/or other recited subject matter that is recited as beingadapted to perform a particular function may additionally oralternatively be described as being configured to perform that function,and vice versa. Similarly, subject matter that is recited as beingconfigured to perform a particular function may additionally oralternatively be described as being operative to perform that function.

As used herein, the phrase “at least one,” in reference to a list of oneor more entities should be understood to mean at least one entityselected from any one or more of the entity in the list of entities, butnot necessarily including at least one of each and every entityspecifically listed within the list of entities and not excluding anycombinations of entities in the list of entities. This definition alsoallows that entities may optionally be present other than the entitiesspecifically identified within the list of entities to which the phrase“at least one” refers, whether related or unrelated to those entitiesspecifically identified. Thus, as a non-limiting example, “at least oneof A and B” (or, equivalently, “at least one of A or B,” or,equivalently “at least one of A and/or B”) may refer, in one embodiment,to at least one, optionally including more than one, A, with no Bpresent (and optionally including entities other than B); in anotherembodiment, to at least one, optionally including more than one, B, withno A present (and optionally including entities other than A); in yetanother embodiment, to at least one, optionally including more than one,A, and at least one, optionally including more than one, B (andoptionally including other entities). In other words, the phrases “atleast one,” “one or more,” and “and/or” are open-ended expressions thatare both conjunctive and disjunctive in operation. For example, each ofthe expressions “at least one of A, B and C,” “at least one of A, B, orC,” “one or more of A, B, and C,” “one or more of A, B, or C” and “A, B,and/or C” may mean A alone, B alone, C alone, A and B together, A and Ctogether, B and C together, A, B and C together, and optionally any ofthe above in combination with at least one other entity.

The various disclosed elements of apparatuses and steps of methodsdisclosed herein are not required to all apparatuses and methodsaccording to the present disclosure, and the present disclosure includesall novel and non-obvious combinations and subcombinations of thevarious elements and steps disclosed herein. Moreover, one or more ofthe various elements and steps disclosed herein may define independentinventive subject matter that is separate and apart from the whole of adisclosed apparatus or method. Accordingly, such inventive subjectmatter is not required to be associated with the specific apparatusesand methods that are expressly disclosed herein, and such inventivesubject matter may find utility in apparatuses and/or methods that arenot expressly disclosed herein.

As used herein, the phrase, “for example,” the phrase, “as an example,”and/or simply the term “example,” when used with reference to one ormore components, features, details, structures, embodiments, and/ormethods according to the present disclosure, are intended to convey thatthe described component, feature, detail, structure, embodiment, and/ormethod is an illustrative, non-exclusive example of components,features, details, structures, embodiments, and/or methods according tothe present disclosure. Thus, the described component, feature, detail,structure, embodiment, and/or method is not intended to be limiting,required, or exclusive/exhaustive; and other components, features,details, structures, embodiments, and/or methods, including structurallyand/or functionally similar and/or equivalent components, features,details, structures, embodiments, and/or methods, are also within thescope of the present disclosure.

1. A system for assembling an elongate composite structure, the systemcomprising: a first rigid elongate cure tool defining a first elongatesupport surface configured to support a first elongate charge ofcomposite material (FEC); a flexible elongate caul plate extending alongthe first elongate support surface and configured to extend between, andspatially separate, the first elongate support surface and the FEC; asecond rigid elongate cure tool defining a second elongate supportsurface configured to support a second elongate charge of compositematerial (SEC), wherein at least a region of the second elongate supportsurface faces toward a corresponding region of the first elongatesupport surface; a translation structure configured to permit relativetranslation between the first rigid elongate cure tool and the secondrigid elongate cure tool from a first relative orientation, in which theFEC is spaced-apart from the SEC, and a second relative orientation, inwhich the FEC contacts the SEC; a vacuum compaction film at leastpartially defining an enclosed volume that includes the FEC, the SEC,and the flexible elongate caul plate, wherein a region of the vacuumcompaction film extends between, and spatially separates, the flexibleelongate caul plate and the first elongate support surface; and a vacuumsource configured to apply a vacuum to the enclosed volume.
 2. Thesystem of claim 1, wherein the system further includes: (i) a firstsealing structure that operatively attaches, and forms a fluid sealbetween, a first edge of the vacuum compaction film and the second rigidelongate cure tool; and (ii) a second sealing structure that operativelyattaches, and forms a fluid seal between, a second edge of the vacuumcompaction film and the second rigid elongate cure tool; wherein thefirst edge of the vacuum compaction film is opposed to the second edgeof the vacuum compaction film.
 3. The system of claim 2, wherein thesecond elongate support surface and the vacuum compaction film togetherdefine the enclosed volume.
 4. The system of claim 1, wherein the vacuumcompaction film is a first vacuum compaction film, and further whereinthe system includes: (i) a second vacuum compaction film at leastpartially defining the enclosed volume; (ii) a first sealing structurethat operatively attaches, and forms a fluid seal between, a first edgeof the first vacuum compaction film and the second rigid elongate curetool; (iii) a second sealing structure that operatively attaches, andforms a fluid seal between, a first edge of the second vacuum compactionfilm and the second rigid elongate cure tool; and (iv) a third sealingstructure that operatively attaches, and forms a fluid seal between, thefirst rigid elongate cure tool and both a second edge of the firstvacuum compaction film and a second edge of the second vacuum compactionfilm.
 5. The system of claim 4, wherein the second elongate supportsurface, the first vacuum compaction film, and the second vacuumcompaction film together define the enclosed volume.
 6. The system ofclaim 1, wherein the flexible elongate caul plate is a first flexibleelongate caul plate, and further wherein the system includes a secondflexible elongate caul plate extending along the second elongate supportsurface and configured to extend between, and spatially separate, thesecond elongate support surface and the SEC, wherein the region of thevacuum compaction film is a first region of the vacuum compaction film,and further wherein a second region of the vacuum compaction filmextends between, and spatially separates, the second flexible elongatecaul plate and the second elongate support surface.
 7. The system ofclaim 6, wherein the system further includes: a sealing structure thatoperatively attaches, and forms a fluid seal between, one of the firstrigid elongate cure tool and the second rigid elongate cure tool andboth a first edge of the vacuum compaction film and a second edge of thevacuum compaction film.
 8. The system of claim 7, wherein the vacuumcompaction film completely defines the enclosed volume.
 9. The system ofclaim 6, wherein the vacuum compaction film is a first vacuum compactionfilm, and further wherein the system further includes: a second vacuumcompaction film at least partially defining the enclosed volume; a firstsealing structure that operatively attaches, and forms a fluid sealbetween, the first rigid elongate cure tool and both a first edge of thefirst vacuum compaction film and a first edge of the second vacuumcompaction film; and a second sealing structure that operativelyattaches, and forms a fluid seal between, the second rigid elongate curetool and both a second edge of the first vacuum compaction film and asecond edge of the second vacuum compaction film.
 10. The system ofclaim 1, wherein the first rigid elongate cure tool has a first curetool stiffness, wherein the second rigid elongate cure tool has a secondcure tool stiffness, wherein the flexible elongate caul plate has a caulplate stiffness, wherein each of the first cure tool stiffness and thesecond cure tool stiffness is at least a threshold multiple of the caulplate stiffness, and wherein the threshold multiplier is at least 100.11. The system of claim 1, wherein the first elongate support surfacedefines a first planar region, a second planar region, and a firstelongate support surface transition region, which transitions betweenthe first planar region and the second planar region, and wherein theflexible elongate caul plate extends across at least a fraction of thefirst planar region, the second planar region, and the first elongatesupport surface transition region.
 12. The system of claim 1, whereineach of the FEC and the SEC includes a corresponding plurality of pliesof composite material that includes a plurality of fibers and a resinmaterial.
 13. The system of claim 1, wherein the flexible elongate caulplate is formed from a plurality of layered plies of composite material.14. The system of claim 1, wherein the flexible elongate caul plate isconfigured to spatially separate an entirety of the first elongatesupport surface from an entirety of the FEC.
 15. The system of claim 1in combination with a heating assembly that defines a heated volume,wherein the heated volume is sized to receive the system, wherein theheating assembly is configured to heat the system, via heating of theheated volume, to cure the FEC and the SEC, to join the FEC to the SEC,and to define the elongate composite structure from the FEC and the SEC,and further wherein the heating assembly includes at least one of anoven and an autoclave.
 16. A method of assembling an elongate compositestructure, the method comprising: positioning a vacuum compaction filmon a first elongate support surface of a first rigid elongate cure tool;positioning a flexible elongate caul plate on the first elongate supportsurface such that the vacuum compaction film extends between, andspatially separates, the flexible elongate caul plate and the firstelongate support surface; positioning a first elongate charge ofcomposite material (FEC) on the first elongate support surface such thatthe vacuum compaction film and the flexible elongate caul plate extendbetween, and spatially separate, the FEC and the first elongate supportsurface; positioning a second elongate charge of composite material(SEC) on a second elongate support surface of a second rigid elongatecure tool; contacting a region of the FEC with a region of the SEC todefine an interface region between the FEC and the SEC; sealing thevacuum compaction film against at least one of the first elongatesupport surface and the second elongate support surface to at leastpartially define an enclosed volume that includes the FEC, the SEC, andthe flexible elongate caul plate; evacuating the enclosed volume tocompact the FEC and the SEC, to press the FEC and the SEC against oneanother, and to generate an elongate composite assembly that includesthe FEC, the SEC, the vacuum compaction film, the first elongate curetool, and the second elongate cure tool; and heating the elongatecomposite assembly to cure the FEC and the SEC, to join the FEC to theSEC within the interface region, and to define the elongate compositestructure from the FEC and the SEC.
 17. The method of claim 16, whereinthe vacuum compaction film is a first vacuum compaction film, whereinthe sealing the first vacuum compaction film includes sealing a firstedge of the first vacuum compaction film against the second rigidelongate cure tool and sealing a second edge of the first vacuumcompaction film against the first rigid elongate cure tool, and furtherwherein the method includes sealing a first edge of a second vacuumcompaction film against the second rigid elongate cure tool and sealinga second edge of the second vacuum compaction film against the firstrigid elongate cure tool such that the first vacuum compaction film, thesecond vacuum compaction film, and the second elongate support surfacetogether define the enclosed volume.
 18. The method of claim 16, whereinthe flexible elongate caul plate is a first flexible elongate caulplate, and further wherein the method includes: prior to the positioningthe SEC, positioning the vacuum compaction film on the second elongatesupport surface; and prior to the positioning the SEC and subsequent tothe positioning the vacuum compaction film on the second elongatesupport surface, positioning a second flexible elongate caul plate onthe second elongate support surface such that the vacuum compaction filmextends between, and spatially separates, the second flexible elongatecaul plate and the second elongate support surface, wherein thepositioning the SEC includes positioning the SEC such that both thevacuum compaction film and the second elongate caul plate extendbetween, and spatially separate, the SEC and the second elongate supportsurface.
 19. The method of claim 18, wherein the vacuum compaction filmis a first vacuum compaction film, and further wherein: the sealing thefirst vacuum compaction film includes sealing a first edge of the firstvacuum compaction film against the first elongate support surface andsealing a second edge of the first vacuum compaction film against thesecond elongate support surface; and the method further includes sealinga first edge of a second vacuum compaction film against the firstelongate support surface and sealing a second edge of the second vacuumcompaction film against the second elongate support surface such thatthe first vacuum compaction film and the second vacuum compaction filmtogether define the enclosed volume.
 20. The method of claim 16,wherein, subsequent to the contacting, at least one of: (i) the FEC andthe SEC define an arcuate transition region therebetween, and furtherwherein, subsequent to the contacting and prior to the sealing, themethod further includes positioning a radius filler within the arcuatetransition region; and (ii) the FEC and the SEC together define anexposed surface, and further wherein, prior to the sealing, the methodfurther includes positioning a base charge on the exposed surface.